Clutch cable issue-need help - Honda Rebel 300 & 500 Forum
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post #1 of 14 (permalink) Old 05-05-2019, 12:46 PM Thread Starter
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Clutch cable issue-need help

Hello everyone, Iíve been following the forums for quite sometime but am a 1st time poster.

I have purchased the chump style handlebars (with brake and clutch extension cables) for my 2018 Rebel 500 from Zeed parts.

I have the install pretty much complete but when I hook up the new clutch cable there is no spring back or really tension of any kind in the handle lever. What am I missing? Any help would be much appreciated thank you.




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post #2 of 14 (permalink) Old 05-05-2019, 01:47 PM
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What happened to this part when you removed the original clutch wire?
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post #3 of 14 (permalink) Old 05-05-2019, 02:18 PM Thread Starter
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Nothing that I can tell


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post #4 of 14 (permalink) Old 05-05-2019, 02:22 PM Thread Starter
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It springs back on its own but just doesnít seem to be enough tension to move the wire. The wire does move pretty freely on its own. I even routed it outside of everything to make sure it wasnít binding.


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post #5 of 14 (permalink) Old 05-05-2019, 02:58 PM
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Quote:
Originally Posted by Jayman View Post


Nothing that I can tell


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If this picture is when you have everything "hooked up", then something is seriously wrong somewhere.
Take note of how the arm sits in the picture I posted.
I took that photo for when I was changing out my levers, to document it's position for if/when I'd have to remove the tension on the wire.
You have 2 places to regulate the tension for the wire when it's connected to the clutch arm. One down where it's connected, and one on the handlebar.
The one on the handlebar should be all the way in, as in not tensioned at all. This one is "strictly" for fine-tuning.
While the one down at the clutch arm is where you'll want to sort out the main tension for the wire.

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post #6 of 14 (permalink) Old 05-05-2019, 03:04 PM Thread Starter
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Any ideas of what could have happened? Everything has been working fine and have had the bike out for plenty of rides this season already. Itís just since I switched out the cable. Very weird. Iíll fart around some more and see what I can come up with


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post #7 of 14 (permalink) Old 05-05-2019, 03:29 PM
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As I mentioned, you have to tension the clutch arm so that it's in the position as the picture I posted.
There is quite a lot of tension on that arm in that position, so judging by your photo you've simply connected the wire to the clutch arm when it's fully out without any tension on it; Meaning it's way bellow the tension it's suppose to have.
I recommend being two people on this, as it was hard for me to keep up the tension on the clutch arm, while adjusting and connecting the clutch wire onto it.
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post #8 of 14 (permalink) Old 05-05-2019, 03:56 PM Thread Starter
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You are absolutely right, the issue is clearly that the clutch cable (wire) that they sent is too long. Even adjusted fully there is still too much slack. Thank you. You guys on this site are fantastic.


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post #9 of 14 (permalink) Old 05-05-2019, 04:00 PM Thread Starter
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Does anyone know if the clutch cable (wire) for the 300 is longer? (Smaller engine maybe set back further). Possibly they sent the cable for that instead of the 500. Iíll keep you posted.


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post #10 of 14 (permalink) Old 05-06-2019, 09:32 AM
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If the issue is that the wire itself is too long, then there is your problem.
But that was not what I was saying here, at all.. I actually can't quite wrap my head around how you made that conclusion..

So for the sake of clarification, I'll try again.

Firstly, the "arm" in the picture that I posted, that is the "Clutch arm". This is what's engaging and disengaging your clutch every time you operate the Clutch lever on the handlebar, which happens through the wire that connects them both.

So this Clutch Arm of yours, when it's fully out and has engaged the clutch, it needs to stay in the position as shown in the picture I posted.
Which means it's still under tension in that position, and it's supposed to be.
But in your case, you have simply connected the wire onto the clutch arm when it's aaaaall the way out, meaning it has no tension on it at all.
Don't you see the difference if you compare your picture against mine? The issue is right there.

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